Optoelectronic component array and method for the production of an optoelectronic component array

ABSTRACT

The invention relates to an optoelectronic component array and to a method for the production thereof. The optoelectronic component array comprises an optoelectronic component arranged on a support element, which is surrounded by a closed dam. An encapsulation is arranged in the inner area of the dam which encapsulates the optoelectronic component and consists of two scaling materials. The inner area of the dam is preferably filled with a first scaling material up to the top edge of the optoelectronic component. The inner area of the dam located above the optoelectronic component is filled with a second transparent scaling material at least in one area of the window.

[0001] The present invention is directed to an optoelectronic component assembly according to the definition of the species in claim 1, as well as to a method for producing an optoelectronic component assembly according to the definition of the species in claim 10.

[0002] An optoelectronic component assembly of the species is known from JP 8-241976. An optoelectronic component, designed as a CCD chip, which is encircled by a concentrically disposed dam, is positioned on a carrier element. The component is connected via bonding wires to conductor lines in the carrier element and, in this way, is electrically contacted. An encapsulation material, made up of two transparent encapsulation materials, is placed in the inner region of the dam. Thermally induced stresses can cause cracks in the encapsulation material and, in some instances, damage the bonding wires. It is, therefore, proposed, in a first step, to introduce a first transparent encapsulation material into the inner region of the dam, to thermally cure this material and, in the process, to eliminate any air bubbles from the encapsulation material. In a second process step, a second transparent encapsulation material is subsequently introduced into the inner region of the dam and thermally cured, in turn, in order to remove any air bubbles present in the second encapsulation material. In this manner, it is possible to ensure that neither of the two encapsulation materials contains any more air bubbles. If, at this point, materials having greatly deviating thermal expansion coefficients are used in a component assembly of this kind, the thermal stresses can produce cracks in the bonding wires. The transparent encapsulation materials or epoxy resins (α=50-70 ppm/K) used, on the one hand, and the materials used for the carrier element and, respectively, the bonding wires (α′=15 ′-25 ppm/K), on the other hand, for instance, have distinctly different expansion coefficients.

[0003] The object of the present invention is, therefore, to devise an optoelectronic component assembly, as well as a suitable method for its manufacture, which will ensure that the bonding wires provided for contacting the optoelectronic component are not damaged even when subject to varying temperatures.

[0004] This first specified objective is achieved by an optoelectronic component assembly having the features set forth in the characterizing part of claim 1.

[0005] Advantageous specific embodiments of the optoelectronic component assembly according to the present invention are derived from the measures delineated in the claims which are dependent upon claim 1.

[0006] The second objective specified is achieved by a method for manufacturing an optoelectronic component assembly in accordance with the measures set forth in the characterizing part of claim 10.

[0007] Advantageous specific embodiments of the method according to the present invention are derived from the measures set forth in the claims which are dependent upon claim 10.

[0008] In accordance with the present invention, a first encapsulation material is introduced into the inner region of the dam, the first encapsulation material advantageously reaching up to the top edge of the optoelectronic component. A second, transparent encapsulation material is introduced over this first material, at least in one spatially defined window region. The first encapsulation material is selected to be preferably different from the second, transparent encapsulation material. A consideration when selecting the first encapsulation material is, in particular, that it have a lowest possible thermal expansion coefficient, which is approximately adapted to the thermal expansion coefficient of the bonding wires and of the carrier element used. In this manner, thermally induced stresses in the region of the bonding wires and, thus, an undesired cracking of the same is avoided.

[0009] In addition, when selecting the first encapsulation material, it proves to be advantageous to select a material which has a roughest possible surface in the cured state. This provides a good adhesion to the second encapsulation material placed above it, which additionally ensures that no thermally produced shearing results between the two encapsulation materials which could potentially damage the bonding wires. In addition, when selecting the first encapsulation material, it is no longer necessary to consider its optical properties, i.e., the material selection may take place solely on the basis of the optimization criteria indicated above.

[0010] One special advantage in the technical production process is derived in one possible specific embodiment of the method according to the present invention when the first encapsulation material and the dam material are made of essentially the same base material and merely have different viscosities, since the first encapsulation material and the dam may then be applied and cured in the same work step.

[0011] Other advantages of the present invention, as well as details pertaining thereto are derived from the following description of exemplary embodiments, on the basis of the attached figures.

[0012] They show:

[0013]FIG. 1 a schematized, sectional view of a first exemplary embodiment of the optoelectronic component assembly according to the present invention;

[0014]FIGS. 2a-2 e each, a method step within the framework of the method of the present invention for manufacturing a second specific embodiment of the optoelectronic component assembly according to the present invention.

[0015] In schematized form, FIG. 1 shows a lateral sectional view of a first specific embodiment of the optoelectronic component assembly according to the present invention. Positioned on a carrier element 1 in this case are the other components of the component assembly, which will be discussed in detail in the following. In this example, carrier element 1 is designed as a known circuit board of FR4 material. Alternatively thereto, other materials come under consideration for carrier element 1, such as FR5, aluminum oxide, glass, etc.

[0016] Not discernible in FIG. 1 are the conductor lines running in carrier element 1 that are used for electrically contacting optoelectronic component 3 positioned on carrier element 1 and any other components that are present. In the illustrated exemplary embodiment, as an optoelectronic component 3, an unhoused component 3 in the form of a photodetector is provided, whose radiation-sensitive surface is oriented away from carrier element 1. Alternatively hereto, a corresponding unhoused light source, a so-called Opto-ASIC or some other optoelectronic element could also be used as an optoelectronic component 3.

[0017] The particular optoelectronic component 3 is connected via bonding wires 4 a, 4 b to the electrical conductor lines in carrier element 1, i.e., electrically contacted in the known manner via bonding wires 4 a, 4 b. In the present example, gold is used as the material for bonding wires 4 a, 4 b. Also usable as bonding wire materials are gold alloys, aluminum, aluminum alloys, or copper.

[0018] In the illustrated exemplary embodiment, optoelectronic component 2 is adhesively mounted on carrier element 1; this bond could alternatively be produced by alloying, eutectic bonding, anodized bonding, soldering or also by welding.

[0019] In addition, the optoelectronic component assembly according to the present invention includes a dam 2 which is positioned on carrier element 1 and encircles or surrounds component 3 in a closed form. Dam 2 may have the most widely varied peripheral geometries; for example, it may surround component 3 in a quadratic form. Alternatively, however, a rectangular, polygonal, or round dam profile around component 3 may also be provided.

[0020] Dam 2 has a height h₂, which, in the present example, is selected to be distinctly greater than height h₁ of component 3. Typical values of heights h₁, h₂ are, for instance, h₁=450 μm and h₂=800 μm.

[0021] An essential function of dam 2 with respect to the component assembly according to the present invention is to form the boundary of the surface required for potting component 3 on carrier substrate 1 using an encapsulation material in the dam inner region. In accordance with the present invention, for the encapsulation, two encapsulation materials 5, 6 are used, which are explained in greater detail in the following. By embedding the component assembly using the two encapsulation materials 5, 6, component 3, as well as bonding wires 4 a, 4 b are protected from mechanical influences.

[0022] As a suitable dam material, a known black epoxy filler substance in the form of a filled epoxy resin may be provided, as sold by the firm Emerson & Cuming under the type designation Amicon 50300 HT. Alternatively, epoxy filler substances of the firm Dexter Hysol may also be used, which are sold under the product identifications FP 4451.

[0023] In the present exemplary embodiment, dam 2 is made of one single dam layer, as is apparent in FIG. 1. Alternatively, however, a two- or multi-layer dam construction could also be provided, as described, for example, in the German Patent Application no. 100 24 336.3. Another option would be to form dam 2 as an injection-molded part.

[0024] Important for the present invention at this point is that the encapsulation material placed in the well-type dam inner region encapsulating optoelectronic component 3 be composed of two different encapsulation materials 5, 6. In this connection, in the illustrated example, the dam inner region is filled more or less up to the top edge of optoelectronic component 3 with a first encapsulation material 5. Accordingly, in the illustrated example, the height of first encapsulation material 5 approximately corresponds to height h₁ of component 3. As a general principle, the height of first encapsulation material 5 may also be somewhat lower. However, one must ensure that the dam inner region is preferably filled at a maximum up to the top edge of optoelectronic component 3 with the first encapsulation material, and, accordingly, that the radiation-sensitive or, as the case may be, radiation-emitting surface of optoelectronic component 3 is also not substantially covered by first encapsulation material 5.

[0025] In accordance with the present invention, first encapsulation material 5 is selected in such a way that its thermal expansion coefficient α_(VM1) is approximately adapted to the thermal expansion coefficient of bonding wires 4 a, 4 b (D) and of carrier element 1 (α_(TE)). For this, a black epoxy filler substance is used, for example, which has a thermal expansion coefficient of α_(VM1)=18-19 ppm/K. Thus, compared to thermal expansion coefficient α_(BD)=15 ppm/K of bonding wires 4 a, 4 b, a very good adaptation is already achieved when gold is used as material for bonding wires 4 a, 4 b. Also, the other materials already mentioned above for bonding wires 4 a, 4 b have thermal expansion coefficients within the range of α_(BD)=[15 ppm/K−25 ppm/K]. In the same way, when FR4 is used as material for carrier element 1, a good adaptation to its thermal expansion coefficient α_(TE)=15 ppm/K is provided. Suitable first encapsulation materials 5 are sold, for example, by the firm Emerson & Cuming or Dexter Hysol under the product description Amicon 50500-1 or FP 4450.

[0026] Accordingly, in the elucidated specific embodiment, first encapsulation material 5 and the material of dam 2 have the same base material and merely have different viscosities. As will be explained further on, from this material selection, advantages also result in the course of a possible specific embodiment of the manufacturing method of the present invention.

[0027] In addition, first encapsulation material 5 is selected to have a greatest possible surface roughness in the cured state. This provides for excellent adhesion to the material situated above it, namely second encapsulation material 6. Second encapsulation material 6 is a commercially available transparent encapsulation material, which is arranged in the inner dam region, at least in a window region above optoelectronic component 3, thus, for example, in the radiation-sensitive region of the photo-element. The product sold by the firm Dexter Hysol under product designation Hysol OS 2800 has proven to be suitable for second encapsulation material 6. Alternatively, the encapsulation materials sold by the same firm under product designations Hysol OS 1600, Hysol OS 1900, Hysol OS 2902, Hysol OS 4000 or Hysol OS 4110 are also suitable for use in this region.

[0028] In the example of FIG. 1, second encapsulation material 6 completely fills up the inner dam region above first encapsulation material 5 and optoelectronic component 3. Alternatively, however, as already mentioned, merely one smaller window region could also be filled with the material.

[0029] The arrangement and selection of encapsulation materials 5, 6 in accordance with the present invention ensure, on the one hand, that the total filling volume in the dam inner region, which must be filled with transparent second encapsulation material 6, is able to be clearly reduced. As explained above, the problems associated with the thermally induced shearing of bonding wires 4 a, 4 b essentially arise because of the greatly differing thermal expansion coefficients of transparent encapsulation materials, on the one hand, and of bonding wires 4 a, 4 b or of carrier element 1, on the other hand. The reduced filling volume also has a positive effect in that the stresses caused during curing by the shrinking process are reduced within the component assembly. In addition, the rough surface quality of first encapsulation material 5 ensures good interlinking with superjacent second encapsulation material 6. As a result, any thermally produced shearing off of two encapsulation materials 5, 6 from one another or cracking of bonding wires 4 a, 4 b is virtually no longer possible.

[0030] Besides the elucidated first specific embodiment of an optoelectronic component assembly, there are, of course, other possible alternative embodiments within the scope of the present invention. A second exemplary embodiment is described in the following in conjunction with FIGS. 2a-2 e, on the basis of which one possible specific embodiment of the method according to the present invention is also described.

[0031] In a first process step shown in FIG. 2a, unhoused optoelectronic component 13 in the form of an opto-ASIC is first positioned on carrier element 10 or the circuit board and bonded thereto. In addition, optoelectronic component 13 is electrically contacted, which, in a generally known manner, may take place via wire bonding and the placement of corresponding bonding wires 14 a, 14 b.

[0032] Dam 12 is subsequently placed on carrier element 10 at height h₂ and, as described above, completely surrounds optoelectronic component 13. The corresponding process step is illustrated in FIG. 2b. The appropriate dam material is applied in this example by a schematically indicated dispensing needle 50 using so-called dispensing technology. As already mentioned, alternatively thereto, a dam or frame element designed as an injection-molded part could also be placed on the carrier element.

[0033] In the case of an application using dispensing technology, the desired height h₂ of dam 12 is able to be set in a defined manner by adjusting the traversing rate of dispensing needle 50 and the applied quantity of the dam material, etc.

[0034] In the subsequent process step illustrated in FIG. 2c, a first encapsulation material 15 is introduced in the dam inner region using dispensing needle 50, advantageously to a maximum height of h₁ of the top edge of the component. As explained above, in this exemplary embodiment, a first encapsulation material 15 is selected which is made of the same base material as dam 12. For example, a black filled epoxy resin or an epoxy filler substance may be used for this purpose. Dam 12, as well as first encapsulation material 15 are subsequently cured using a suitable annealing process.

[0035] In the following process step shown in FIG. 2d, in contrast to the first described exemplary embodiment, an additional glass plate 19 is placed on the radiation-sensitive surface of component 13 or of the opto-ASIC. This may be accomplished, as indicated in FIG. 2d, before the dam region is filled with the second transparent encapsulation material. Alternatively, however, glass plate 19 may first be pressed onto the surface of component 13 following completion of any residual filling of the dam inner region with the transparent second encapsulation material.

[0036] In the case of components 13 having unpassivated active surfaces, the placement of glass plate 19 protects or seals these surfaces. Moreover, by selecting the thickness of glass plate 19 to be large enough, an additional mechanical protection may be ensured for bonding wires 14 a, 14 b. Alternatively to the described exemplary embodiment, the glass plate may, of course, also have a larger thickness and then project slightly out of the second encapsulation material.

[0037] In the next process step illustrated in FIG. 2e, the remaining dam inner region is finally filled with second encapsulation material 16 using dispensing needle 70, more or less up to the top dam edge, for which purpose, as explained above, a transparent encapsulation material is used.

[0038] Within the framework of the present invention, there are, of course, also alternative variants in addition to the elucidated specific embodiments. 

What is claimed is:
 1. An optoelectronic component assembly, comprised of a carrier element (1, 10), an optoelectronic component (3; 13) which is positioned on the carrier element (1; 10) and which is connected via bonding wires (4 a, 4 b; 14 a, 14 b) to conductor lines in the carrier element (1; 10), an enclosed dam (2; 12) which is situated on the carrier element (1; 10) and surrounds the optoelectronic component, (3; 13), an encapsulation material which is placed in the dam inner region, encapsulates the optoelectronic component (3; 13) and includes two encapsulation materials (5, 6; 15, 16), wherein the dam inner region is filled up to the top edge of the optoelectronic component (3; 13) with a first encapsulation material (5; 15); and the inner dam region above the optoelectronic component (3; 13) is filled, at least in a window region, with a transparent second encapsulation material (6; 16).
 2. The optoelectronic component assembly as recited in claim 1, wherein the first encapsulation material (5; 15) has a thermal expansion coefficient (α_(VM1)) which is approximately adapted to the thermal expansion coefficient (α_(BD)) of the bonding wires (4 a, 4 b; 14 a, 14 b) and to the thermal expansion coefficient (α_(TE)) of the carrier element (1; 10).
 3. The optoelectronic component assembly as recited in claim 1, wherein the first encapsulation material (5; 15) has a thermal expansion coefficient of α_(VM1)=18−19 ppm/K.
 4. The optoelectronic component assembly as recited in claim 1, wherein the first encapsulation material (5; 15) has a substantial surface roughness in the cured state.
 5. The optoelectronic component assembly as recited in claim 1, wherein the first encapsulation material (5; 15) is a black epoxy filler substance.
 6. The optoelectronic component assembly as recited in claim 1, wherein the first encapsulation material (5; 15) and the material of the dam (2; 12) are made of the same base material and merely have different viscosities.
 7. The optoelectronic component assembly as recited in claim 1, wherein the second encapsulation material (6, 16) completely fills up the inner dam region above the first encapsulation material (5; 15) and the optoelectronic component (3; 13).
 8. The optoelectronic component assembly as recited in claim 1, wherein the optoelectronic component (3; 13) is designed as a photo-element or opto-ASIC whose radiation-sensitive surface is oriented away from the carrier element (1; 10).
 9. The optoelectronic component assembly as recited in claim 8, wherein a glass plate (19) is placed directly on the radiation-sensitive surface of the photo-element or opto-ASIC.
 10. A method for manufacturing an optoelectronic component assembly, an optoelectronic component (3; 13) being first positioned on a carrier element (1; 10); an enclosed dam (2; 12) being subsequently placed on the carrier element (1; 10) around the optoelectronic component (3; 13); and an encapsulation material composed of two encapsulation materials (5, 6; 15; 16) being introduced into the inner dam region and encapsulating the optoelectronic component (3; 13), wherein to introduce the encapsulation material, initially a first non-transparent encapsulation material (5; 15) is introduced into the inner dam region at a maximum up to the top edge of the optoelectronic component (3; 13) and, subsequently, the inner dam region above the optoelectronic component (3; 13) is filled, at least in a window region, with a transparent second encapsulation material (6; 16).
 11. The method as recited in claim 10, wherein a first encapsulation material (5; 15) is selected which has a thermal expansion coefficient (α_(VM1)) which is approximately adapted to the thermal expansion coefficient (α_(BD)) of the bonding wires (4 a, 4 b; 14 a, 14 b) and to the thermal expansion coefficient (α_(TE)) of the carrier element (1; 10).
 12. The method as recited in claim 10, wherein a first encapsulation material (5; 15) is selected which has a thermal expansion coefficient of α_(VM1)=18−19 ppm/K.
 13. The method as recited in claim 10, wherein a first encapsulation material (5; 15) is selected which has a substantial surface roughness in the cured state.
 14. The method as recited in claim 10, wherein a black epoxy filler substance is selected as a first encapsulation material (5; 15).
 15. The method as recited in claim 10, wherein the second encapsulation material (6; 16) is introduced into the complete inner dam region above the first encapsulation material (5; 15).
 16. The method as recited in claim 10, wherein the optoelectronic component (3; 13) is electroconductively connected to conductor tracks in the carrier element (1; 10). 